Abstract
Selective laser melting (SLM) is an additive manufacturing method with rapid solidification properties, which is conducive to the preparation of alloys with fine microstructures and uniform chemical compositions. Magnesium alloys are lightweight materials that are widely used in the aerospace, biomedical and other fields due to their low density, high specific strength, and good biocompatibility. However, the poor laser formability of magnesium alloy restricts its application. This paper discusses the current research status both related to the theoretical understanding and technology applications. There are problems such as limited processable materials, immature process conditions and metallurgical defects on SLM processing magnesium alloys. Some efforts have been made to solve the above problems, such as adding alloy elements and applying postprocessing. However, the breakthroughs in these two areas are rarely reviewed. Due to the paucity of publications on postprocessing and alloy design of SLMed magnesium alloy powders, we review the current state of research and progress. Moreover, traditional preparation techniques of magnesium alloys are evaluated and related to the SLM process with a view to gaining useful insights, especially with respect to the postprocessing and alloy design of magnesium alloys. The paper also reviews the influence of process parameters on formability, densification and mechanical behavior of magnesium. In addition, the progress of microstructure and metallurgical defects encountered in the SLM processed parts is described. Finally, this article summarizes the research results, and with respect to materials and metallurgy, the new challenges and prospects in the SLM processing of magnesium alloy powders are proposed with respect to alloy design, base material purification, inclusion control and theoretical calculation, and the role of intermetallic compounds.
Highlights
Magnesium is one of the most abundant elements on Earth and represents approximately 2.5% of its composition
In the past two years, these three issues of selective laser melted (SLMed) magnesium alloys have been substantially improved by optimizing process parameters, introducing post treatment and adjusting different alloying elements
The formation of magnesium alloy in the Selective laser melting (SLM) process of each region is Strong balling zone: SLM forming in the range of high scanning speeds or low laser powers, which is characterized by insufficient heating of the magnesium alloy powder, and the temperature of some powders does not reach the melting point temperature and fails to completely melt [26]
Summary
Magnesium is one of the most abundant elements on Earth and represents approximately 2.5% of its composition. SLM uses a high-energy laser beam to completely melt metal powder in a protective atmosphere along a defined laser path, and this molten metal rapidly solidifies [10]. By repeating this step and overlapping subsequent layers, a three-dimensional component is eventually formed. Due to several characteristics of magnesium alloys, including a low melting point, easy oxidation, and dangerous production, research on the preparation of these materials is still in its infancy worldwide. Process conditions and new research progress on relative density, microstructure, mechanical properties and corrosion resistance of SLMed magnesium alloys will be reviewed. This article discusses the aspects that need to be addressed in future research on SLMed magnesium alloys, which provides a basis for further research and development of these materials
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